Mobile cxhibition and lecture complex

Joint project implemented together with ОАО RZD (Russian Railways) in 2011.

For Russia, with its large distances and scattered towns, the railway is the key communicator not only in the economic sphere but also in the humanitarian sphere. Despite the development of modern telecommunication technologies, when everything, irrespective of your location, can be seen on the television or in the Internet, nothing can substitute for a live - face to face - observation of what is interesting to you.

There are two ways make this happen. You either go to see the interesting thing yourself, which is not always comfortable and sometimes is expensive. Or you wait until this interesting thing comes to you. The mobile exhibition trains which are gaining popularity these days help to implement such option which is comfortable in every respect. These trains help the Russians who live away from the cultural and scientific centers to become familiar with the best specimens of cultural and historic heritage, with the ground-breaking scientific and technical achievements. To see for yourself how the country lived yesterday, lives today and mostly important how it will live tomorrow. This is particularly important for the young Russians who will create this tomorrow.

The objective of the mobile exhibition of innovative achievements project is to demonstrate the national innovations and technologies and also to present Russian companies and state monopolies as large customers and users of high-tech equipment. According to the authors of the idea and the project developers, the Mobile Exhibition and Lecture Complex (PVLK) was supposed to become a powerful tool for delivering the information on the latest achievements of culture, science and technology to the most remote parts of Russia.

The foundation for the development of the Mobile Exhibition and Lecture Complex (PVLK) was laid by such Federal Target Programs as The Research and Development in Priority Fields of S&T Complex of Russia in 2007 - 2012, National Technology Base for 2007-2011, National Innovation System and other documents which establish the directions for the innovation-driven development of Russia.

The development of the train cost nearly half a billion of roubles and the project was implemented in the record-breaking time – the path from the idea to its implementation took only eight months.

After winning the tender for the project, the TVEMA specialists commissioned the finished complex to the Customer in the shortest possible time. On 3 August 2011, the Mobile Exhibition and Lecture Complex (PVLK) began its first journey from Rizhsky railway station in Moscow.

Since the moment of its creation, the Mobile Exhibition and Lecture Complex (PVLK) has travelled for 166.366 km. It visited 329 cities on 16 Russian railways (including Kaliningrad railway where the complex was delivered by a ferryboat) and also visited such CIS countries as Kazakhstan and Belarus. During this time the exhibition was visited by 386.452 people, including 218.778 young people and children.

Today, the Mobile Exhibition and Lecture Complex (PVLK) regularly travels on the entire network of the Russian railways. Its exhibition is updated quarterly and it demonstrates the latest solutions applied for upgrading both railway and other industries of the Russian economy.

Self-propelled track geometry laboratory on the basis of the VL-11M electric locomotive

Joint project implemented together with ОАО RZD (Russian Railways) in 2012.

The annual increase in the tonnage of the freight traffic sets new tasks for the subdivisions responsible for the railway track maintenance.

The increasing axial loads, the mass and the length of the freight trains and the use of high-speed trains on the railways nowadays call for a mandatory inspection of the tracks under load to detect the areas with high dimensional instability.

The effective instrument for such inspection is a dedicated self-propelled track geometry laboratory developed by TVEMA engineers together with the Department of Technical Policy of ОАО RZD. The laboratory is built on the basis of VL-11m main-line electric freight locomotive.

The project objective is to create a laboratory for measuring track irregularities under the axial load 23 tonnes, taking into account the elastic displacement of the rails. The differences in the readings from the various inspection devices at the same track sections characterise the irregularity of elastic displacement of the rails and provide detection of the track sections with variable stiffness, backlash, and other defects.

The Company specialists specially adapted all measurement systems for installation on the electric locomotive. One of the locomotive sections was converted into a space for the workshop compartment, auxiliary and amenity rooms.

Two monitoring and measurement systems were installed on the locomotive.

SVOD-2 system for high-speed visual inspection which detects the defects of the permanent way, and SOKOL-2 high-speed system for track geometry assessment which monitors and analyses the track parameters, inter alia:

• track gauge;

• level;

• alignments;

• sag;

• rail wear;

• rail cant;

• track plane and profile.

When used together, both systems based on the differences in the geometry parameters of the track under load and without load provide detection of the sections where the actual condition of the track structural elements and the roadbed does not ensure the stability of the track geometry. All captured data is processed by URRAN and CASCADE automated systems.

The information acquired by the self-propelled track geometry laboratory based on VL11m locomotive is meant to facilitate the improvement of the track maintenance system and to optimize the planning of comprehensive repair works.

Rail lubrication vehicles

Joint project implemented together with ОАО RZD (Russian Railways) in 2010-2013.

In 2010, TVEMA launched the production of a new generation of rail lubrication vehicles under a resource conservation program of ОАО RZD (Russian Railways).

The project objective is the development of a new generation of a rail lubrication vehicle for lubrication of curved rails at the main tracks with high density of freight traffic. The project was implemented together with the Department of Technical Policy of ОАО RZD.

The rail lubrication vehicle is built on the basis of a compartment carriage manufactured by OAO Tverskoy Vagonostroitel'nyi Zavod (Tver Carriage-building Factory). The vehicle can be operated in any season and any time of day, in conditions of snow and rainfall, at temperatures ranging from -40°C to +50°C.

To select the most efficient vehicle layout and the composition of the rail lubrication equipment, the vehicle during design was conditionally split into the following units.

A comparative analysis was performed for each unit to select the most efficient option. Currently the vehicle comprises:

1 unit – including the lubricant stock and storage area;

2 unit – including the work area;

3 unit – including the amenity area;

4 unit – including the technical area;

5 unit – including the underfloor equipment.

The vehicle comprises: the rail lubrication assembly, the system for visual control of the lubrication process, main and backup power supply sources, connection to external AC power supply (220, 380 V), technical rooms, amenity rooms, sanitary and hygienic rooms, water supply system, vehicle heating system, fire-fighting system, and radio communication system.

The vehicle is equipped with the video monitoring system to control the application of the lubricant on the rails. The system comprises the external unit equipped with the video cameras and installed on the bogie frame, and the monitor with the video recorder installed in the workshop compartment.

The video monitoring system ensures the visual control of the lubricant application process at any time of day. The vehicle has several power supply sources. The main power supply source is the underfloor generator 50 V, 8.2 kW, the battery pack, and the inverter 220 V, 6 kW. The backup power supply source is the diesel generator 5.5 kW, 220 V. Fuel tank ensures the continuous operation of the diesel generator and the vehicle heating system at a haul distance of 5000 km. Power supply system provides possibility for connecting to the external single-phase power supply source, 220 V via a power cable.

Advantages of the rail lubrication vehicle project:

• reduced operating costs due to replacement of rail lubrication locomotives with the rail lubrication vehicles;

• 10 times cheaper operation compared to the rail lubrication locomotive;

• increased train driving safety due to improved wheel directional stability;

• increased wheel and rail lifetime due to reduced wear rate;

• reduced fuel and energy consumption for the haulage operations due to reduced tractive resistance on the curves;

• reduced noise level on the curves.

Furnishing of deutsche bahn ag ndt trains with visual inspection systems

Joint project implemented together with Deutsche Bahn AG (Germany) in 2013.

On 20 March 2013, the TVEMA specialists completed the works under a joint project which envisaged furnishing of NDT rains (SPZ1 и Netz - Schienenprüfzug1) of the German holding Deutsche Bahn AG with SVOD-2 system for high-speed visual inspection.

The implementation of this joint project became possible when in December 2011 TVEMA won the international tender for furnishing NDT trains of DB AG with video systems for continuous monitoring of rail heads. Competing for a prestigious order, the Company beat such largest suppliers of diagnostic equipment for the European railway market as Mermec, BVSys and DB Systemtechnik.

With implementation of the joint project for launching SVOD-2 system for high-speed visual inspection, Deutsche Bahn AG specialists confirmed the correctness of their choice to use our video system at the German railways.

Today, SVOD-2 is the fastest system for inspection of the rail treads. Ultra-high-speed linear cameras of the system provide the image resolution better than 0.2 mm per pixel in both planes at speeds above 100 km/h. The dedicated illumination system ensures capture of a clear and well-contrasted image at any time of the day and in every kind of weather.

The contract for furnishing German NDT trains with SVOD-2 system for high-speed visual inspection became the first step in establishing cooperation between TVEMA and the German holding Deutsche Bahn AG.

Both sides of this project acknowledged this step as a huge success.

Diagnostic lab combined course-based Mercedes-Benz Unimog

Mitial project with «Mercedes-Benz Trucks» and JSC «Russian Railways» was implemented in 2014.

The company TVEMA and «Mercedes-Benz Trucks», a leading German manufacturer of all-terrain vehicles for several years together working to create innovative diagnostic systems for the Railways of Russia and Germany. As a result of this collaboration in 2014 with the participation of JSC «RZD» a project was implemented diagnostic lab combined course-based car Rover Mercedes-Benz Unimog.

The laboratory is intended for diagnostics of railway infrastructure using systems processing with a speed up to 40 km/h. In the course of its movement laboratory clarifies the parameters of the studied section of railway track (coordinates milepost, crossings, turnouts, etc.) and generates and transmits the status to the relevant services for their future work. At the expense of the equipment combined stroke lab can move both on-road (highway, off-road) and the railroad tracks.

Diagnostic combined lab consists of:

- locomobile Mercedes-Benz Unimog;

- module nondestructive testing;

- complex high-speed three-dimensional scanning «GABARIT-M».

Portable engine Mercedes-Benz Unimog - rail machine, offering a unified view of the four-wheeled machinery with a diversified set of capabilities. No other car has so many options of operation as the Unimog. Installation of additional equipment at both the front and rear in a variety of combinations makes this unit most capable of all possible transport. Due to the possibility of choosing between the railroad tracks and a road Unimog has increased mobility, while remaining completely full rail vehicle. At the same time, due to the low costs of operation and maintenance, this machine is cost-effective.

The NDT-testing module -is intended for diagnostics of a condition of rails laid in the path of the wooden and concrete Foundation and is an intelligent automated system for ultrasonic diagnostics using pulse-echo and mirror-shadow methods of control at speeds up to 30 km/h.

The module provides the hardware and software signal processing control diagnosed rails to their registration and remembering for long-term storage for later analysis, as well as registration information about the traversed path. Identifies the following types of defects for the classification of defects and damages of rails NTD/CPU-1-93: 11, 18, 20, 21, 24, 25, 26.3, 27, 30B, 30G, 38, 50, 52, 53, 55, 56.3, 60, 66.3, 70, 74, 79, at UIC Code712 R: UIC111/211, UIC411.1/421/431, UIC471/481,UIC112/212, UIC113/213, UIC133/233, UIC132.1/232.1, UIC132.2/232.2, UIC135/235/236, UIC154/254, UIC100/200, UIC301/302, UIC412/422, UIC127/237, UIC125/225, UIC124/224, UIC133/233, UIC154/254.

Complex high-speed three-dimensional scanning "GABARIT-M" is designed for regular high-speed monitoring tunnels and bridges, a dimension check and megaputer distances, as well as analysis of the parameters of the ballast and subgrade. The complex may include both high-speed and high-speed scanning system. To perform a wide range of tasks, the company's experts recommend the use of high-speed scanning system.

High-speed scanning system - specially designed for harsh environments, the system allows year-round measurements of the infrastructure at speeds up to 140 km/h with a step between measurements is not more than 0.2 meters In the system is based on laser scanner operating on the principle of measuring the phase shift. Integration capabilities of the system provide implementation of functions such as sharing scan data and information from vision systems and poaisnenia. One of the main advantages of our systems scanning – unique multi-module software.

Software modules form the following analytic and reporting data needed for effective infrastructure management:

- two-dimensional and three-dimensional display of the measured phase with the video overlay of the occurrences of the objects in the specified envelope – zone and size;

- measured miuute distance;

- determining deviations in the shape of the ballast and subgrade;

- two-dimensional and three-dimensional displays tunnels with automatic detection of defects on the walls;

- the position of the contact wire;

- report on the oversized field;

- report on the state of the tunnel;

- report on the status of ballast and subgrade;

- general report on the state of the site.

The economic effect from the introduction of the complex is achieved by reducing time and labor costs, and improve the accuracy of measurements. So, for example, that the traditional way to analyze the 500-kilometer stretch of track for the presence of oversized seats, violations megaputer distance, the outlines of ballast and subgrade requires tens of specialists and months of work. «SIZE-M», controlled by one operator, analyzes a similar plot in one day.

Railway LAB Ultrasonic Test TVEMA 70

Joint project of TVEMA and CSR Qishuyan Locomotive Chinese Co, Ltd Chinese factory (realized in 2016)

Project's aim is to design an optimum diagnostic automobile rail car tailored to the specifics of high-speed railways and subways of PRC.

In 2013 JSC "Firma TVEMA" and CSR Qishuyan Locomotive Chinese Co, Ltd Chinese factory launched the initiation of joint project for production of diagnostic equipment for railways and subways of People's Republic of China. A major focus of work was design and manufacturing of diagnostic automobile rail car for subway's needs. In May 2014 after presenting this Project the partners surpassed such American competitors as Sperry Rail Service and Rail Depcons and won the corresponding tender of the Beijing Subway, and in July 2016 "Railway LAB Ultrasonic Test TVEMA 70" automobile rail car got started on monitoring of Beijing Subway's track. This success was largely determined by the work on the project itself – during all the preparatory phase company's specialist in cooperation with representatives of the Embassy of Russia in PRC, the Trade Mission of the Russian Federation in PRC and the Ministry of Transport of Russia convinced Chinese partners that our equipment was significantly less expensive in use and much more accurate and reliable in its measurement than American one.

New automobile rail car fully complies with international standards of thermal, vibration and sound insulation. The automobile rail car is supplied with up-to-date diagnostic equipment by JSC "Firma TVEMA" and ensures most comfortable and safe working conditions for crew. For this purpose, the automobile rail car is provided with modern air conditioning and heating systems, autonomous power supply system, system of the wire warning and individual security and other life support systems.

The automobile rail car can travel along railway track with speeds over 100 km/h in a temperature range of -40 - +40 °C.

Teamwork in the frame of a joint project is continuing and TVEMA's management believes that foresaid project's realization will let the Company establish itself successfully on the Chinese market and will stimulate further Company's active PRC's markets expansion, as well as will contribute to TVEMA objective of providing itself as a leading supplier of diagnostic equipment to railways and subways of People's Republic of China.

Diagnostic train DJ NDT for Czech railways

The joint project of TVEMA with Czech Railways with the participation of AV Engineering, CZ Loko and NDCon Logic (Czechia), the Diagnostic Center of the Hungarian Railways MAV KFV and PLR Magdeburg (Germany), was implemented in 2017.

The aim of the project is to create an optimal diagnostic unit adapted to the peculiarities of the railways and subways of the EU countries.

Since March 2017 the newest diagnostic train DJ NDT - a unique symbioses control equipment performed by leading manufacturing companies from different countries – has been running on Czech Railways lines. Designing of the train diagnostic system was launched by JSC "Firma TVEMA" jointly with the Czech Railways two years ago. Apart from TVEMA and Czech Companies AV Engineering, CZ Loko and NDCon Logic, Diagnoctic Center of the Hungarian Railways MAV KVF and German Company PLR Magdeburg participated in the project. Thus, for the first time representatives of four European countries have collectively created united diagnostic complex.

In addition to our equipment, which includes an advanced flaw detector ECHO-COMPLEX-2, line-scan cameras (two cameras per each thread), searching system with acoustic units and a software, there are used Hungarian NDT bogie and German eddy current system. Moreover, for the Hungarian bogie, which provides centering of flaw detection equipment, our specialists have designed special searching systems ensuring monitoring of rails, switches, expansion joints and other elements of the track of the Czech Railways at operating speed up to 80 km/h. Test procedures proved 100% detectability of the flaws by means of our equipment. During working runs, more than 1000 km of track of different kinds were checked. And again, the accuracy and precision of monitoring results were shown. Thus, the high efficiency of our diagnostic system was confirmed. Foreign partners and supervisors highlighted its ease of use and reliability, as well as its operating convenience.

Our colleagues commended specifically our software. It makes the operation of a train easy and, combining ultrasonic and visual-optical methods of nondestructive testing, assures automated deciphering of the results. Both registration and decoding of data become a simple and fascinating procedure. In addition, concomitantly with flaw detector's ECHO-COMPLEX-2 hardware capabilities, the "smart" software for the first time in the practice of European ultrasonic control eliminates the need for sensitivity adjustments. Now it can be done automatically in the entire range of operating speeds, which greatly simplifies the operator's activities during the run.

The implementation of this project is a milestone for both TVEMA Company and the sphere of non-destructive testing in Europe in general. After all, the use of our products by the EU country indicates its high quality and opens up good prospects for the Company in the development of the European market. We are already discussing with the Czech colleagues the possible retrofitting of the DJ NDT train with additional systems, as well as the likelihood of further projects to create new diagnostic tools.